Shell-and-Tube Heat Exchanger Geometry Modification: An Efficient Way to Mitigate Fouling

Abstract

Crude oil fouling of a shell-and-tube heat exchanger sized according to TEMA standard is compared to a No-Foul design under industrial operating conditions. For similar operating conditions, TEMA and No-Foul heat exchangers have the same behavior regarding fouling. Since the No-Foul one has less tubes by design for the same heat duty, shear stress is increased. Consequently, the No-Foul heat exchanger is less prone to fouling at the same throughput. Impact of tube bundle geometry is then investigated. Helically finned tubes are compared to plain tubes in the No-Foul heat exchanger. Under similar operating conditions, fouling rates measured are up to an order of magnitude lower than plain tubes (respectively 10−11 and 10−10 m2 K/J). However, pressure drop across the tube-side in both No-Foul plain and finned setup are increased in comparison to the TEMA heat-exchanger.